Self-priming surfacing composition for finished surfaces

Abstract

A surfacing composition made of recycled paint, which requires no priming, has a non-reflective “flat” appearance, and is partially composed of dried paint. The composition provides a useful application for used or excess household paint, which would otherwise require special methods of disposal and potentially create future toxic cleanup problems. The composition is made of granular dried paint and a water-based sealer, which can be spread on a surface to repair imperfections. The surface can then be finished, and no priming is required. Due to the composition's flat appearance, the patch does not display any characteristic sheen where the repair has been made. The composition provides a simple means of recycling paint, and provides a simple and inexpensive means of repairing imperfections in walls and other surfaces while saving the step of priming the patch before painting or repainting.

I claim: 
     
       1. A surfacing composition for repairing a surface or preparing an unfinished surface, the composition comprising a sealer and a mixed alkyd/acrylic granular dried paint. 
     
     
       2. The surfacing composition of  claim 1 , wherein the mixed alkyd/acrylic granular dried paint is a product of a process comprising:
 a. combining a granular dried acrylic paint with a liquid alkyd paint to form a wet paste; 
 b. drying the wet paste to form a dried paste; and 
 c. grinding the dried paste to form a mixed alkyd/acrylic granular dried paint. 
 
     
     
       3. The surfacing composition of  claim 1 , wherein the volumetric ratio of granular dried acrylic paint to liquid alkyd paint is exactly 3:1 or about 3:1. 
     
     
       4. The surfacing composition of  claim 2 , wherein the granular dried acrylic paint is the product of the process comprising:
 a. obtaining a dried acrylic paint; and 
 b. grinding the dried acrylic paint to form a granular dried acrylic paint. 
 
     
     
       5. The surfacing composition of  claim 4 , wherein obtaining a dried acrylic paint further comprises:
 a. obtaining a liquid acrylic paint; and 
 b. drying the liquid acrylic paint to form the dried paint. 
 
     
     
       6. The surfacing composition of  claim 5 , wherein the liquid acrylic paint is dried by: (a) subjecting the liquid acrylic paint to an increased temperature, (b) fanning the liquid acrylic paint, (c) subjecting the liquid acrylic paint to a low pressure, (a) and (b), (a) and (c), (b) and (c), or (a), (b) and (c). 
     
     
       7. The surfacing composition of  claim 6 , wherein the increased temperature is at least one of the following: about 100-750° F., about 200-600° F., about 250-500° F., and about 500° F. 
     
     
       8. The surfacing composition of  claim 2 , further comprising blending the wet paste during drying. 
     
     
       9. The surfacing composition of  claim 8 , wherein blending the wet paste comprises blending the wet paste for at least two minutes. 
     
     
       10. The surfacing composition of  claim 1 , wherein the surfacing composition consists essentially of the sealer and the mixed alkyd/acrylic granular dried paint. 
     
     
       11. The surfacing composition of  claim 1 , wherein the sealer comprises a water-based acrylic sealer. 
     
     
       12. The surfacing composition of  claim 11 , wherein the sealer further comprises at least one: of a styrene-acrylic resin, a pigment, texanol, styrene copolymer, limestone, titanium oxide, quartz, and formaldehyde. 
     
     
       13. The surfacing composition of  claim 1 , wherein the volumetric ratio of mixed alkyd/acrylic granular dried paint to sealer is selected from the group consisting of: about 40-80%, about 50-70%, about 55-65%, and about 60%. 
     
     
       14. The surfacing composition of  claim 1 , wherein about 90% of the mixed alkyd/acrylic granular dried paint has a diameter selected from the group consisting of: about 2.0 mm, about 0.18-2.0 mm, and about 0.17-0.7 mm. 
     
     
       15. The surfacing composition of  claim 1 , wherein the composition displays an eliminated or reduced distinguishing characteristic indicating where composition has been applied. 
     
     
       16. The surfacing composition of  claim 15 , wherein the distinguishing characteristic is a sheen. 
     
     
       17. A surfacing composition for repairing a surface to be finished, the composition comprising:
 a. a sealer comprising by weight about 20-30% limestone, about 5-10% titanium oxide, about 0.1-1.0% quartz, about 1-5% texanol, about 5-10% styrene copolymer, about 0.01-0.10% formaldehyde, about 40-50% water, and about 5-10% styrene acrylic copolymer; and 
 b. a mixed alkyd/acrylic granular dried paint comprising a product of a process consisting of:
 i. obtaining a liquid acrylic paint, subjecting the paint to an elevated temperature of about 500° F. to form a dried paint, and grinding the dried paint to form a granular dried acrylic paint; 
 ii. combining three parts by volume of the granular dried acrylic paint with one part by volume of liquid alkyd paint, to form a wet paste; 
 iii. drying the wet paste to form a dried paste; and 
 iv. grinding the dried paste to form a mixed alkyd/acrylic granular dried paint; 
 
 wherein the surfacing composition comprises about 25% sealer by volume. 
 
     
     
       18. A method of repairing a surface, the method comprising
 a. applying the surfacing composition of  claim 1  to a portion of an area to repaired containing a defect to be repaired, to produce a repaired surface; 
 b. allowing the composition to dry; and 
 c. finishing the repaired surface; 
 wherein the repaired area is not primed prior to finishing. 
 
     
     
       19. A method of applying a surfacing composition to a surface, comprising:
 a. applying the surfacing composition of  claim 1  to an area of the surface; 
 b. allowing the surfacing composition to dry, and 
 c. finishing a portion of the area of the surface. 
 
     
     
       20. The method of  claim 19 , wherein the method is a method of repairing a surface to be finished, wherein the area of the surface to be applied is a repaired area, and wherein the portion of the area to be finished is the repaired area. 
     
     
       21. The method of  claim 20 , wherein the repaired area is not primed after applying and prior to finishing. 
     
     
       22. The method of  claim 19 , wherein the surface is selected from the group consisting of: drywall, metal, metal frame, plaster, concrete, cement board, stucco, stone, artificial stone, fiber cement, vinyl, PVC, wood, wood composite, aluminum composite, brick, adobe, cannabrick, cast earth, cast stone, cob, earthen plaster, glass, tile, asphalt, terra cotta, and ceramic. 
     
     
       23. The method of  claim 20 , wherein a repaired area displays an eliminated or reduced distinguishing characteristic indicating where composition has been applied or wherein an unfinished surface displays an eliminated or reduced distinguishing characteristic indicating where the composition has been applied after the unfinished surface has been finished. 
     
     
       24. The method of  claim 23 , wherein the distinguishing characteristic is a sheen. 
     
     
       25. The method of  claim 18 , wherein the method is a method of plastering a surface to be finished, wherein the area of the surface to be applied is a surface in need of plastering, and wherein the portion of the area to be finished is at least a portion of the surface in need of plastering. 
     
     
       26. The method of  claim 19 , wherein the method is a method of jointing two intersecting surfaces, wherein the area of the surface to be applied is the intersection of the two surfaces, and wherein the portion of the area to be finished is at least a portion of the intersection of the two surfaces. 
     
     
       27. The method of  claim 19 , wherein the method is a method for filling or covering a gap in a surface, wherein the area of the surface to be applied is a gapped portion of the surface, and wherein the portion of the area to be finished is the gapped portion of the surface. 
     
     
       28. A kit comprising the surfacing composition of  claim 1 . 
     
     
       29. The kit of  claim 28 , wherein the kit is for at least one of: repairing a surface to be painted, plastering a surface to be painted, and jointing two intersecting surfaces.